Thin-Film Solar Cell Module
The invention relates to a thin-film solar cell module (71) in which a layer (72) of TCO is applied on a glass substrate (73). On this layer (72) of TCO is disposed a semiconductor layer (75) on which is applied an electrically conducting backside layer (85). The backside layer (85) includes a bridge element (88) in contact with the layer (72) of TCO. Directly on the layer (72) of TCO are applied busbars (82) by means of a printing method. The busbars (82) are herein connected with the backside layer (85) via the layer (72) of TCO.
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The invention relates to a thin-film solar cell module according to the preamble of patent claim 1.
A solar cell is a large-area exemplary form of a photovoltaic element in which the incident radiative power of sunlight is directly converted into electric power. The conversion of the radiative power into electric power rests on the internal photoelectric effect of a semiconductor material. Silicon has been found to be especially suitable as starting material for solar cells. Apart from mono- and polycrystalline silicon, amorphous silicon has increasingly also been utilized for the production of solar cells. Tandem cells are also utilized as solar cells. More recently, so-called thin-film solar cells are also applied, which are approximately 100 times thinner than solar cells of silicon wafers, and which are comprised, for example, of gallium arsenide (GaAS), cadmium telluride (CdTe) or amorphous silicon.
A conventional solar cell is, for example, 100 mm wide, 100 mm long and 0.25 mm thick. On the front side of this square solar cell are located, for example, several contact fingers which are connected with their one end to a common contact finger busbar. This busbar is coupled with a contact connector which is also connected to an adjacent solar cell. The contact connector is enclosed with its solar cell-side end between a semiconductor and a cover glass with antireflective coating (cf. WO 2005/004242 A2).
The busbar is a thin filament resting on a metal layer or another electrically well conducting layer. Since the electric power of the solar cell is conducted toward the outside via the busbar, the quality of the electrical connection between busbar and metal layer is of great significance for the efficiency of the solar cell. This electrical connection is conventionally established by means of soldering, welding or adhesion. All three methods are labor intensive and can only be automated with difficulty.
In addition to the conventional solar cells, there are also so-called thin-film solar cells produced by coating a substrate. Herein, for example, a glass sheet is provided with layers of electrically conducting or semiconducting materials which are only a few μm thick. The discrete layers are here applied using various processes. After each coating step the particular layer is divided into basic structures of thin material strips in order to produce a series circuit of the layers of the complete solar cell module.
The separation of the conducting or semiconducting layers can be carried out by means of lasers or by means of mechanical or chemical means. A thin-film solar cell is substantially comprised of a layer of TCO (=Transparent Conductive Oxides), a semiconductor layer (for example amorphous silicon=a-Si) and a metal layer. The TCO utilized is preferably ITO, ZnO or SnO2. However, amorphous silicon can also be utilized together with microcrystalline silicon (μSi) or cadmium telluride (CdTe) or copper indium diselenide (CIS).
The metal layer serving as the back electrode is, for example, comprised of molybdenum, aluminum.
A method for the production of series-connected thin-film solar cells is already known, in which onto a large area of a substrate successively a first electrode layer, at least a layer of a semiconductor material, and a second electrode layer are applied and wherein the layers are structured for their interconnection (DE 37 12 589 A1). Herein the first electrode layer is structured before the further layers are applied. The structuring here is comprised of the chemical conversion of parallel strips or of the ablation of such strips. Parallel to these strips are applied strips of conducting pastes (stitch bars), which have the function in a finished thin-film solar cell assembly have the function to establish the electrically conducting connection between the first electrode layer and a second electrode layer, such that the discrete thin-film solar cells are connected in series.
A method for the production of a thin-film solar cell structured thusly, which comprises one or several transparent layers, is disclosed, for example, in EP 0 536 431 A1. In this method a laser-induced material ablation is carried out. The material is directly irradiated with a suitable laser, wherein the ablation of the material takes place by vaporization. For the material ablation the irradiation takes place with a laser pulse through the transparent layer with a wavelength in the absorption range of the thin layer. The irradiated thin-film area, together with optionally superjacent layers, is ablated from the transparent layer leaving no residues.
In a further known method for the series interconnection of thin-film solar cells, strip-shaped cells are formed with operating voltages of, for example, 0.7 V, with which cells with operating voltages of, for example, 12 V/24 V, thus series interconnected, can be produced (EP 0 232 749 A2=U.S. Pat. No. 4,745,078 A). This method is intended to circumvent the difficulties that occur upon the separation of the amorphous silicon layer and the subsequent selective separation of the metal layer by means of a laser.
Further known is a series-interconnected thin-film solar cell module of crystalline silicon, whose front electrodes are generated by means of screen printing and in which the series interconnection is established via contact grooves (DE 37 27 825 A1).
Until now only metal filaments have been employed as busbars, which had been applied on the metal layers of the thin-film solar cell modules. However, applying these metal filaments on the thin-film solar cell modules is highly labor intensive and the application can only be automated with difficulty. These metal filaments can further be easily detached from the thin-film solar cell module since the connection between the metal layers and the metal filaments was only very weak. A further problem comprises that through the structure of the thin-film solar cell modules provided with metal filaments, bubbles are frequently formed if onto the thin-film solar cell module further layers are applied.
The present invention therefore addresses the problem of providing a thin-film solar cell module in which the conventional metal filaments are replaced by busbars whose thickness is very low and which are securely disposed on the thin-film solar cell module.
This problem is resolved according to the features of patent claim 1.
The invention consequently relates to a thin-film solar cell module in which a layer of TCO (Transparent Conductive Oxides) is applied on a glass substrate. On this layer of TCO is disposed a semiconductor layer on which is applied an electrically conducting backside layer. The backside layer comprises a bridge element in contact with the layer of TCO. Directly on the layer of TCO are applied busbars by means of a printing method. The busbars, however, can also be directly disposed on the glass substrate. The busbars are connected with the backside layer via the layer of TCO. It is also feasible to apply the busbars on the backside layer.
The advantage of this invention comprises that the busbars can be applied very simply on the thin-film solar cell module. The application of these busbars takes place by printing methods, for example using an inkjet printing method. These printing methods can be readily automated and are therefore cost-effective. The thus produced busbars have a very low thickness and are directly in contact on the metal layer of the thin-film solar cell modules. However, it is also feasible to dispose the busbars within the thin-film solar cell module. If the thin-film solar cell modules are provided with a protective layer, no bubble formation occurs any longer. These thin-film solar cell modules according to the invention, further, have a high long-term stability.
Embodiment examples of the invention are shown in the drawing and will be described in further detail in the following.
In the drawing depict:
The two ribbon cables as well as the insulating tape are not shown in
The production of the solar cell module 1 depicted in
A glass substrate 4 is prepared and thereon a layer 5 of TCO is applied which covers the glass substrate 4 completely. The layer 5 is subsequently treated in very specific regions with a laser. This laser has a wavelength corresponding to the absorption range of layer 5. By treating the layer 5 with a laser a strip-form portion of the layer 5 is ablated whereby gaps are formed such as for example gap 48 evident in
Busbars 2, 3 can be applied using a screen printing method or a thermal transfer printing method. However, the busbars 2, 3 can also be disposed by means of an inkjet printing method on the backside layer 63. The principle of the inkjet printing method is described, for example at the website http://www.conductiveinkjet.com. In this method a catalytic layer is applied in the form of a strip onto the margin regions 32, 33. These strips have already the desired composition of the busbars. After the strips have been applied, they are cured by means of UV. The glass substrate 4 coated with several layers is subsequently introduced into an electrolytic solution. In this solution a film grows autocatalytically in the region of the strips. The process is terminated when the strips have the desired size.
A further laser treatment subsequently takes place, whereby the gaps 59, 61 and 62 are formed.
On the backside layer 63 an insulating tape is subsequently disposed on which two ribbon cables are disposed (cf. in this connection
The production of the thin-film solar cell module 71, again, takes place by preparation of the glass substrate 73 and subsequent coating of the glass substrate 73 with TCO, whereby the layer 72 is formed. At the two opposite margin regions the busbars are subsequently applied using a printing method, for example, a screen printing method, a thermal transfer printing method or an inkjet printing method.
Layer 72 is subsequently treated with a laser of suitable wavelength such that a structured layer 72 is formed which includes several gaps, of which in
The difference between the solar cell module 91 and the two solar cell modules 1 and 71 thus lies therein that in the solar cell module 91 the two busbars are disposed directly on the glass substrate 92. The application of the two busbars on the glass substrate 92 can therein, again, take place for example by means of a screen printing method, a thermal transfer printing method or an inkjet printing method, wherein the application of the busbar 103 represents the first production step in the case of the exemplary form according to
Although in the embodiment examples the layers are each ablated using a laser, it is obvious to a person of skill in the art that the layers can also be ablated using other methods, for example by etching of the layers.
The ribbon cables are either to be connected with the busbars or with the backside layer. It is obvious to a person of skill in the art that the ribbon cables can be connected with the backside layer as well also with the busbars. In the embodiment examples according to
The advantage of these thin-film solar cell modules according to the invention is consequently their simple and cost-effective production, since in simple manner an electrical connection between the busbars and the electrically conducting backside layer can be established.
In the thin-film solar cell modules according to the embodiment examples there is always the assurance that between the busbars and the backside layer an electrical connection is established. Thus, as is evident in
Those skilled in the art can readily recognize that numerous variations and substitutions may be made in the invention, its use and its configuration to achieve substantially the same results as achieved by the embodiments described herein. Accordingly, there is no intention to limit the invention to the disclosed exemplary forms. Many variations, modifications and alternative constructions fall within the scope and spirit of the disclosed invention as expressed in the claims.
Claims
1. Thin-film solar cell module (1, 71, 91) comprising characterized in that at least two busbars (2, 3; 82; 103) located opposite one another are provided, which are connected with the backside layer (63, 85, 104) and are applied by using printing methods.
- a) a layer (5, 72, 93) of TCO applied on a glass substrate (4, 73, 92),
- b) a semiconductor layer (10, 76, 97) disposed on said layer (5, 72, 93) comprised of TCO, and
- c) an electrically conducting backside layer (63, 85, 104) applied on the semiconductor layer (10, 76, 97), wherein the backside layer (63, 85, 104) is connected with the layer (5, 72, 93) of TCO via bridge elements (22-24, 88; 89, 106; 107),
2. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the busbars (2, 3) are disposed on the backside layer (63).
3. Thin-film solar cell module (71) as claimed in claim 1, characterized in that the busbars (82) are disposed on the layer (72) of TCO.
4. Thin-film solar cell module (71) as claimed in claim 3, characterized in that the busbars (82) are disposed adjacent to a bridge element (88), wherein the layer (72) of TCO connects the bridge element (88) with the busbar (82), and the distance (A) between the busbar (82) and the bridge element (88) is less than the width (b) of the busbar (82).
5. Thin-film solar cell module (71) as claimed in claim 3, characterized in that the busbars (82) are in contact with a bridge element (88).
6. Thin-film solar cell module (91) as claimed in claim 1, characterized in that the busbars (103) are disposed on the glass substrate (92).
7. Thin-film solar cell module (91) as claimed in claim 6, characterized in that the busbars (103) are at least partially encased by the layer (93) of TCO.
8. Thin-film solar cell module (91) as claimed in claim 7, characterized in that the busbars (103) are disposed adjacent to a bridge element (106), wherein the layer (93) of TCO connects the bridge element (106) with the busbar (103), and the distance (A) between the busbar (103) and the bridge element (106) is less than the width (b) of the busbar (103).
9. Thin-film solar cell module (71) as claimed in claim 6, characterized in that the busbars (103) are in contact with a bridge element (106).
10. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the busbars (2, 3; 85; 103) are disposed at oppositely located margin regions (32, 33) of the thin-film solar cell module (1, 71, 91).
11. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the backside layer (63, 85, 104) comprises a three layer system comprising the layers of ZnO and Al and NiV.
12. Thin-film solar cell module (1) as claimed in claim 1, characterized in that the two ribbon cables (64, 65) are disposed on an insulating tape (66) disposed between the ribbon cables (64, 65) and the backside layer (63).
13. Thin-film solar cell module (1) as claimed in claim 1, characterized in that one ribbon cable (64, 65) each is in contact with one of the busbars (2, 3).
14. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the printing method is an inkjet printing method.
15. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the printing method is a screen printing method.
16. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the printing method is a thermal transfer printing method.
17. Thin-film solar cell module (1, 71, 91) as claimed in claim 1, characterized in that the backside layer (63, 85, 104) comprises a three layer system comprising the layers of ZnO and Ag and NiV.
Type: Application
Filed: Apr 16, 2009
Publication Date: Oct 21, 2010
Applicant:
Inventors: Axel Straub (Ingelheim), Tobias Repmann (Alzenau)
Application Number: 12/425,128
International Classification: H01L 31/00 (20060101);